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"project Cosworth" - Ford Sierra Cosworth 4x4


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#436 c00mes30

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Posted 02 September 2012 - 04:42 PM

Wow! This is going to be epic! Keep it up :ohno:

#437 kmol468

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Posted 10 October 2012 - 07:26 PM

Things are moving forward, its finally being assembled and the car is off to paint

Steering rack rebuilt on cleaned engine cradle and uprated engine mounts fitted

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Note the solid steering mounts!

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The engine is next on the hit list. Ive been ripping it to bits, cleaning it up and refitting it with better uprated parts... bigger turbo, injectors, tubular manifold, ARP bolts..... all the bits I have been stock piling are finally being used. Anyhow the pictures:

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Head off and half cleaned, not how many of those bloody exhaust studs either are broken or came out with the nut! It extracts the urine!
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Finally after searching for a 1" socket and a 27mm spanner I can get rebuilding (after more cleaning)

Oh yeah bodyshop photos:

Skimmed engine bay

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Both sides hiding those nasty welding deformations on both rear quarters

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Oh and a sneak preview of the arches:

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Lots of things still to do, but more little jobs, but im felling things are getting there

Edited by kmol468, 10 October 2012 - 07:29 PM.


#438 thelegg

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Posted 11 October 2012 - 07:17 PM

looking great, cracking build mate cant wait to see this on the road/track

#439 evansisgreat

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Posted 14 October 2012 - 06:02 PM

NIce one, this gets better with each post.

#440 kmol468

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Posted 18 October 2012 - 08:01 PM

Despite my best efforts to move along with things by rebuilding the head. I've been thwarted as I haven't got a recessed valve spring compressor. So I've left it to pick up another day.
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#441 M J W J

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Posted 19 October 2012 - 02:24 PM

Spark plug socket and lump hammer works well to get valves out (intact as well).

Put the socket on the spring and give it a good sharp hit. As the spring compresses the collets should pop out and the valve will be released from the spring. I've done engines this way and it does save time. It will get you moving along while waiting for a valve spring compressor to turn up in the post or until you can go out and buy one.

You will need a valve spring compressor for reassembly though.

#442 hoody99

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Posted 19 October 2012 - 11:05 PM

This's epic good on you for following through with your first idea of this so long ago lol

#443 kmol468

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Posted 30 October 2012 - 05:11 PM

Ive been doing some light tinkering today despite feeling under the weather.

I have managed to get all the valves out and the stem seals. (thanks for the handy tip MJWJ, it came in useful)
Im going to replace the valve stem seals as the engine is in pieces and now is the best time to do it. Also at the time of purchase it was abit smokey, so ive dug out the new seals and placed them to one side ready for fitment.

Upon removal all the inlet valves and valve seats look in good condition although the complete exhaust side look pretty appalling. I know they are the exhaust side and will get clogged but I think a good clean and re-seat is in order. Take a look....

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#444 MiniLandy

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Posted 30 October 2012 - 05:37 PM

Hard to tell from just pictures, but those exhaust valves look pretty rough, just re lapping them might not be enough.

Might be worth changing the valve guides and getting the seats recut if it was smokey and they don't come good from being relapped!

Good to see an update though, watching with interest.

#445 M J W J

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Posted 31 October 2012 - 12:19 PM

Glad it worked. As said before you can't get them back in this way.

Just check where your tappets go back in that you haven't left any burs. I did once and couldn't figure out why the tappet wouldn't go down. I had to massage the head with a needle file in the end.

#446 kmol468

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Posted 14 January 2013 - 03:35 PM

Okay, so things are moving forward, notably the arches are sorted. They are yet to be fitted but here are a few pictures of the arches first, then the molds.

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They might not be the norm for mini arches but they couldnt be straight as the width of them would result in them starting near the rear window level!
So to cover the wheels they have got the initial mini wheel arch bulge and then they extend with a slight taper to them. The last picture shows the arches with some reference of width.
Now just a lick of paint and I will be pleased.

#447 Alex_B

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Posted 14 January 2013 - 04:31 PM

Wow those are mini miglia shaped arches, that are about the size of a complete mini miglia!

looking good, can't wait to see the end result, been following this since day one!

#448 domdee

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Posted 24 January 2013 - 04:12 PM

nice build

#449 kmol468

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Posted 26 January 2013 - 03:17 PM

Just been down to see the arches........
They are a tad wide! Lol
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Oh as a shameless plug, if anyone wants some uber wide arches made, just get in touch.

#450 rally515

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Posted 26 January 2013 - 03:22 PM

HOVER MINI ^^ ABOVE ^^ hover arches avalible on sale soon. :lol:
Sorry couldnt resist :P




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